Southwire BENDMAX BML-2000 Manual

OPERATING and MAINTENANCE
INSTRUCTIONS
BENDMAX™
Compact Power Bender
(BML-2000)
READ AND UNDERSTAND ALL THE
INSTRUCTIONS AND SAFETY INFORMATION IN
THIS MANUAL BEFORE OPERATING OR
SERVICING THIS TOOL
07/17 (BML-2000)
2017

1
TABLE OF CONTENTS
Description .................................................................................2
Safety .........................................................................................2
Purpose of this Manual...............................................................2
Important Safety Information………………………………….…3-8
Grounding Instructions………….….…………………….…...…...9
Identification..............................................................................10
Features.....................................................................................11
Transportation...........................................................................11
Setup……………………………………………………….............12
Operation................................….……….….……….............13-14
Bending……………………….….……….….………….......…14-16
Specifications............................................................................17
Troubleshooting........................................................................18
Warranty..............................................................................19-20
2
DESCRIPTION
The Southwire BENDMAX™ Compact Power Bender is intended to
bend 3/4" to 2" conduit and pipe. This bender has the capability to
accommodate the following types of conduit and pipe:
• Electrical Metallic Tubing
• Intermediate Metallic Conduit
• Galvanized Rigid Conduit
SAFETY
Safety is essential in the use and maintenance of Southwire Tools
and Equipment. This instruction manual and any markings on the
tool provide information for avoiding hazards and unsafe practices
related to the use of this tool. Observe all the safety information
provided.
WARNING - Read and understand all instructions and safety infor-
mation in this manual before operating or servicing this tool.
PURPOSE OF THIS MANUAL
This manual is intended to familiarize all personnel with the safe
operation of the Southwire BENDMAX™ Compact Power Bender.
Keep this manual available to all personnel. Replacement manuals
are available at no charge at www.southwiretools.com.
All specifications are nominal and may change as design improve-
ments occur. Southwire Company, LLC shall not be liable for dam-
ages resulting from misapplication or misuse of its products.

• Do not use in dangerous environment. Do not use power tools in
damp or wet locations, or expose them to rain. Keep work area
well lighted.
• Do not immerse the pendant switch in water or any other liquid.
3
IMPORTANT SAFETY INFORMATION
4
IMPORTANT SAFETY INFORMATION
FAILURE TO OBSERVE THESE WARNINGS COULD RESULT
IN SEVERE INJURY OR DEATH.
WARNING
This symbol is used to call your attention to hazards or unsafe
practices which could result in an injury or property damage. The
signal word, difined below, indicates the severity of the hazard. The
message after the signal word provides in formation for preventing
or avoiding the hazard.
DANGER
WARNING
CAUTION
WARNING：
• Inspect the power cord before use. Repair of replace the cord if
damaged.
• Connect the power cord to a 120 volt, 20 amp receptacle on a
ground fault protected circuit only. Refer to “Grounding
Instructions”.
• Do not modify the power cord or plug.
• Disconnet the unit from power before servicing.
- Immediate hazards which, if not avoided,
WILL result in severe injury or death.
- Hazards which, if not avoided, COULD
result in severe injury or death.
- Hazards or unsafe practices which, if not
avoided, MAY result in injury or property damage.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
WARNING
• Read and understand all instructions and safety information in
this manual before operating or servicing this tool.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
• Do not use this tool in a hazardous environment. Hazards include
flammable liquids, gases, or other materials. Using this tool in a
hazardous environment can result in a fire or explosion.
FAILURE TO OBSERVE THESE WARNINGS WILL RESULT
IN SEVERE INJURY OR DEATH.
DANGER
Electric Shock Hazard

5 6
• Always use safety glasses. Everyday glasses only have impact
resistant lenses; they are NOT safety glasses. When using in
dusty environment, use face or dust mask.
IMPORTANT SAFETY INFORMATION IMPORTANT SAFETY INFORMATION
FAILURE TO WEAR EYE PROTECTION COULD RESULT IN
SERIOUS EYE INJURY FROM FLYING DEBRIS.
WARNING
• For continued protection against risk or fire and electric shock,
replace ONLY with same manufacturer, type, and rating of fuse.
Refer to the “ Maintenance” section of this manual.
FAILURE TO OBSERVE THIS WARNING COULD RESULT
IN SEVERE INJURY OR DEATH.
WARNING
• Reduce the risk of unintentional starting. Make sure switch is in
off position before plugging in.
• Never leave tool running unattended. Turn power off. Do not
leave tool until it comes to a complete stop.
• Disconnect tools before servicing and when changing
accessories such as shoes, rollers, and the like. Accidental
start-up could result in serious injury.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
WARNING
• Never stand on tool. Serious injury could occur if the tool is
tipped.
• Do not overreach. Keep proper footing and balance at all times.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
WARNING
• Keep hands away from bending shoe, rollers, and conduit when
bender is in use.
• Support conduit when unloading. Conduit can become loose
and fall if not properly supported.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
WARNING:
• Keep guards in place and in working order.
• Remove any tools from bender before operating. Form habit of
checking to see that all tools are removed from bender before
turning it on.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
WARNING
Pinch Points

7 8
• Use only three-wire, 12 AWG extension cords that have three-
prong grounding-type plugs and three-hole receptacles that
accept the tool`s plug.
• Do not use extension cords that are longer than 30m(100``).
• Repair or replace damaged extension cords.
IMPORTANT SAFETY INFORMATION IMPORTANT SAFETY INFORMATION
FAILURE TO OBSERVE THIS WARNING COULD RESULT
IN SEVERE INJURY OR DEATH.
WARNING:
• Select the appropriate shoe groove and support roller for the
type and size of conduit before bending.
• Do not bend conduit over 96 degrees. Overbending could result
in the other shoe hook colliding with the conduit.
FAILURE TO OBSERVE THIS WARNING COULD RESULT
IN SEVERE INJURY OR DEATH.
CAUTION
• Inspect the bender before use. Replace worn, damaged, or
missing parts with Southwire replacement parts. A damaged or
improperly assembled component could break and strike nearby
personnel.
CAUTION
• Adjust fork spacing to match fork tubes on bender. Ensure
front wheel brakes are engaged before inserting forks into fork
tubes.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
WARNING
• Conduit moves rapidly as it is bent. The path of the conduit must
be clear of obstructions. Be sure clearance is adequate before
starting the bend.
• Wear proper apparel. Do not wear loose clothing, gloves, neckties,
rings, bracelets, or other jewelry which may get caught in moving
parts. Nonslip footwear is recommended. Wear protectice hair
covering to contain long hair.
• Do not force rollers or alter tool. It will do the job better and sager
at the rate for which it was designed.
• Use the right tool. Do not force tool or attachment to do a job for
which it was not designed.
• Use this tool for the manufacturer`s intended purpose only. Use
other than that which is instructed in this manual can result in
injury or property damage.
FAILURE TO OBSERVE THESE PRECAUTIONS MAY
RESULT IN INJURY OR PROPERTY DAMAGE.
CAUTION
• Maintain tools with care. Keep tool clean for best and safest
performance. Follow instructions for lubricating and changing
accessories.
• Check damaged parts. Before further use of the tool, a guard or
other part that is damaged should be carefully checked to
determine that it will operate properly and perform its intended
function. Check for alignment of moving parts, binding of moving
parts, breakage of parts, mounting, and any other conditions that
may affect its operation. A guard or other part that is damaged
should be properly repaired or replaced.
FAILURE TO OBSERVE THESE PRECAUTIONS MAY
RESULT IN INJURY OR PROPERTY DAMAGE.
Extension Cords

109
GROUNDING INSTRUCTIONS IDENTIFICATION
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
WARNING:
• Do not modify the plug provided with the tool.
• Connect this tool to a grounded receptacle on a 20 amp ground
fault protected circuit.
This tool must be grounded. In the event of a malfunction or
breakdown, an electrical ground provides a path of least resistance
for the electric current. This path of least resistance is intended to
reduce the risk of electric shock.
This tool’s electric cord has a grounding conductor and a grounding
plug as shown. Do not modify the plug. Connect the plug to a
corresponding receptacle that is properly installed and grounded in
accordance with all national and local codes and ordinances. Do not
use an adapter.
Do not modify the plug provided. If it will not fit the outlet, have the
proper outlet installed by a qualified electrician. Improper
connection of the equipment-grounding conductor can result in a
risk of electric shock. The conductor with insulation having an outer
surface that is green with or without yellow stripes is the
equipment-grounding conductor. If repair or replacement of the
electric cord or plug is necessary, do not connect the
equipment-grounding conductor to a live terminal. Check with
qualified electrician or service personnel if the grounding
instructions are not completely understood, or if in doubt as to
whether the tool is properly grounded.
BML-2000 IDENTIFICATION-FRONT BML-2000 IDENTIFICATION-BACK
BML-2000 IDENTIFICATION
1. 3/4``-2`` EMT,IMC/GRC
bending shoe
2. Bending hooks (EMT- Gray)
(IMC/GRC Black)
3. Analog protractor
4. Manual bender buttons
5. Bender support handle
6. Fork rings
7. Squeeze adjustment lever
8. Roller assembly loch handle
9. 1-1/2`` -2`` EMT/IMC roller
10. Fixed rigid rollers
11. Power receptacle
12. Hand pendant
13. Bender control cable
14. 15 Amp fuse
15. Power switch
16. Push cart handle
17. Motor
18. Gearbox
19. Fixed caster
20. Swivel caster
21. Caster brake
13
15
12
11
18
17
16
14
3
7
5
4
2
1
19
21
6
20
8
9
10
Electric Shock Hazard

1211
FEATURES SET UP
• Single shoe bending of 3/4" to 2" EMT, IMC/GRC conduit.
• Four sturdy casters for easy transportability.
• Squeeze adjustment allows for variations in conduit.
• Front locking casters to securely keep bender in place during use.
• Hand pendant and front button controls for multiple bending
applications.
TRANSPORTING OF BENDER
Refer to the “Identification” section of this manual.
To transport the BENDMAX™ Compact Bender on the ground
1. Unlock Caster Brakes (21) and use Push Cart Handle (16) to
maneuver bender to desired location.
2. Lock Caster Brakes (21) when transport is complete.
To transport the BENDMAX™ Compact Bender with Forklift
1. Ensure Caster Brakes (21) are in the locked position.
2. Insert fork lift arms into fork rings located under bender cart.
Lift bender to transport around the jobsite.
Refer to the “Identification” section of this manual.
1. Position the bender so there is room to load conduit and
engage the front Caster Brakes (21).
2. Plug approved 12 AWG extension cord into the Power Recep
tacle (11) from grounded 20-amp outlet.
• Adjust fork spacing to match fork rings on bender. Ensure
front wheel brakes are engaged before inserting forks into fork
rings.
• Ensure forks go under front and back support bars and through
fork rings to prevent bender from moving once lifted by forklift.
WARNING
FAILURE TO OBSERVE THIS WARNING COULD RESULT
IN SEVERE INJURY OR DEATH.
WARNING
WARNING:
• Always use safety glasses. Everyday glasses only have impact
resistant lenses; they are NOT safety glasses. When using in
dusty environment, use face or dust mask.
FAILURE TO WEAR EYE PROTECTION COULD RESULT IN
SERIOUS EYE INJURY FROM FLYING DEBRIS.
• Use only three-wire, 12 AWG extension cords that have three-
prong grounding-type plugs and three-hole receptacles that
accept the tool`s plug.
• Do not use extension cords that are longer than 30m (100``).
• Repair or replace damaged extension cords.
FAILURE TO OBSERVE THIS WARNING COULD RESULT
IN SEVERE INJURY OR DEATH.
3. Plug the Pendant Control Cable (13) into housing under Power
Switch (15). Bender will operate by either Hand Pendant (12) or
manually pressing the Manual Bending Buttons (4).
Extension Cords

1. Turn bender “ON” by pressing the green Power Switch (15).
1413
OPERATION OPERATION
NOTE: Fixed Rigid Rollers (10) should be in the up (engaged)
position during all bends regardless of type or size of conduit
being bent.
BENDING
1. When bending 1-1/2", or 2" EMT or IMC, the amount of squeeze
applied to the conduit can be adjusted to compensate for conduit
variations. The squeeze is adjustable by pulling pin and rotating
the Squeeze Adjustment Lever (7) to increase or decrease the
amount of tension needed to properly seat the conduit as shown
in (Fig 11).
2. Counterclockwise turns of the lever will decrease pressure applied
to conduit while clockwise turns of the lever will increase pressure
to the conduit.
SQUEEZE ADJUSTMENT
• Keep hands away from bending shoe, rollers, and conduit when
bender is in use.
• Support conduit when unloading. Conduit can become loose
and fall if not properly supported.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
WARNING:
DANGER
DANGER:
• Do not use this tool in a hazardous environment. Hazards include
flammable liquids, gases, or other materials. Using this tool in a
hazardous environment can resul in a fire or explosion.
FAILURE TO OBSERVE THESE WARNINGS WILL RESULT
IN SEVERE INJURY OR DEATH.
• Inspect the power cord before use. Repair of replace the cord if
damaged.
• Connect the power cord to a 120 volt, 20 amp receptacle on a
ground fault protected circuit only. Refer to “Grounding
Instructions”.
• Do not modify the power cord or plug.
• Disconnet the unit from power before servicing.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
NOTE: Use position of the pull pin to index squeeze setting.
Do not use handle position as the reference point.
NOTE: Test bend should be performed to ensure proper
squeeze is set. Minor adjustments may be required.
Fig 11
Pinch Points
Electric Shock Hazard
Refer to the “Identification” section of this manual
Refer to the “Identification” section of this manual

1615
BENDING BENDING
2. Use the Manual Bender Buttons (4) on front of bender or the
Hand Pendent (12) to orient the shoe so that the hooks of the
conduit type to be bent are at the 7 o’clock (approximately –5°)
position on the analog protractor.
3. Ensure proper orientation of the Bending Shoe (1) by
positioning the Gray hooks at the 7 o’clock position for EMT
conduit or the Black hooks at the 7 o’clock position for IMC and
GRC conduit.
4. Load the conduit into the appropriate sized Fixed Rigid Roller (10)
and groove (Fig 12) so that the bending mark is aligned with the
front edge of the hook as shown in (Fig 13).
5. Bending the conduit.
Fig 15
Fig 16 Fig 17
Fig 12 Fig 13
Fig 14
DEDUCT CALCULATIONS
Note: Test bends should be performed to ensure proper conduit
squeeze is set. Minor adjustments may be required.
To adjust the conduit squeeze pressure, refer to section labeled
“SQUEEZE ADJUSTMENT”.
DEDUCT
Conduit EMT RIGID/IMC
3/4``
1``
1-1/4``
1-1/2``
2``
8-3/4``
10-5/8``
12-13/16``
15-1/8``
16-3/8``
8-3/4``
10-7/8``
12-5/16``
14-7/8``
16-3/8``
A. While bending ¾” through 2” EMT, IMC, or GRC conduit,
ensure the Fixed Rigid Rollers (10) are in the upright
position, as shown in (Fig 14 and 15). Fixed Rigid Rollers
(10) should only be “DOWN” position to help in unloading of
the conduit after a bend has been completed. Return Fixed
Rigid Rollers (10) to the “UP” position once conduit has
been removed in preparation for next bend.
B. When bending 1-1/2" and 2" EMT or IMC conduit, use the
1-1/2”-2” EMT/IMC Roller (9) by turning the assembly to
reflect “E” for EMT or “I” for IMC. Roller Assembly Lock
Handle (8) may have to be pulled to the left to allow roller
assembly to be rotated (Fig 16). Once properly selected,
raise the rollers from the retracted position to the upright
(engaged) position by rotating the Roller Assembly Lock
Handle (8) counter clockwise to lock and secure conduit in
place, as shown in (Fig 17). Slight pressure to handle may
be required at the start of the bend. Handle should lock into
place once bending shoe starts to rotate.
DOWN UP
Pull handle
to left
Rotate to
“E” to “I”

1817
SPECIFICATIONS
SPECIFICATIONS
TROUBLESHOOTING
ADDITIONAL ITEMS
A. Personal protective equipment
B. Portable band saw or another conduit cutting device
C. Appropriate reamer or filing tool
D. Tape measure
E. Black marker
F. Magnetic level (Southwire MCB Level)
G. EMT, IMC or GRC conduit
• Model# BML2000
• Stock# 64-60-12-01
• Name- BENDMAX™ Compact Power Bender
• Length- 38”
• Width- 30”
• Height- 50”
• Weight- 516 lb. (234kg)
PROBLEM CAUSE DIAGNOSIS CURE
1
Bender will not
operate
Power source
Check for voltage at
power source
If power is on, go to
(#3)
2 No power at bender
Defective extension
power cord
Ohm extension cord
for broken wire
Replace extension
cord
3
Power to bender
will not operate
Power switch in the
off position
Check power switch
is lite green when in
the "ON" position
Replace switch
Fuse blown Inspect 15 amp fuse Replace fuse
Motor defective
Check for power at
motor
Replace motor
4
5
Motor runs but
will not bend
Defective gear box Motor running but
no output through
gear box
Replace gear box
Chain from transfer
shaft broken
Remove cover and
visually check for
broken parts
Replace broken
parts
Key between motor
and gearbox missing
Remove motor
from gearbox
Replace key
Chain from jack
shaft to shoe
sprocket broken
Remove cover and
visually check for
broken parts
Replace broken
parts
Bender operates in
only one direction
Defective
Bend/Return switch
Ohm switch for open
contact or shorted
contacts
Replace pendant
Defective pendant
cord
Ohm for broken
wire
Replace pendant
cord

2019
Warranty Claim Information/How Do You Get Service?
For all warranty, customer service, and product return authorizations and inquiries,
please contact Southwire’s Tools & Assembled Products at:
Southwire Tools & Assembled Products
840 Old Bremen Road
Carrollton, GA, 30117
Phone Number: 1.855.SW.Tools
Repair Your Product When it is Out of Warranty
Southwire is happy to provide information about where a purchaser can send a product for
repair at consumers’ own expense, please contact 1.855.SW.tools or visit
www.southwiretools.com/tools/home.do for more information about servicing for Southwire
Products.
WARRANTY ON
SOUTHWIRE CONTRACTOR EQUIPMENT
What Does This Warranty Cover?
Five-Year Limited Warranty on Contractor Equipment
Under Southwire’s Contractor Equipment 5-Year Limited Warranty, Southwire Company, LLC
warrants that all Southwire Contractor Equipment will be free from manufacturer defects for a
period of five (5) years from the date of the original end user’s purchase. However, electrical
components and consumable parts such as ropes, blades, dies, draw studs, grips, are
excluded from this 5-Year Limited Warranty and are subject to the One -Year warranty terms.
Under this 5-Year Limited Warranty, the following are also excluded and Southwire
Company, LLC will have no liability for any of the following: normal wear and tear resulting
from product use and damage arising out of misuse, abuse, modification, and improper
product maintenance. This warranty also does not cover Southwire Contractor Equipment
products that have been modified by any party other than Southwire Company, LLC or its
authorized third party designee. This 5-Year Limited Warranty is not transferrable to or
enforceable by any person other than the product’s original end user.
One-Year Limited Warranty on Electrical Components and Consumable
Parts (with 5-Year warranty)
Under Southwire’s 1-Year Limited Warranty, Southwire Company, LLC warrants that all
electrical components and consumable parts such as ropes, blades, dies, draw studs, grips
will be free from manufacturer defects for a period of one-year from the date of the original
end user’s purchase. Under this 1-Year Limited Warranty, Southwire Company, LLC will have
no liability for any of the following: normal wear and tear resulting from product use and
damage arising out of misuse, abuse, modification, and improper product maintenance. This
warranty also does not cover Southwire electrical components and consumable parts that
have been modified by any party other than Southwire Company, LLC or its authorized third
party designee. This 1-Year Limited Warranty is not transferrable to or enforceable by any
person other than the product’s original end user.
Exclusion of Incidental, Consequential, Indirect, Special and Punitive Damages
SOUTHWIRE MAKES NO WARRANTY THAT SOUTHWIRE CONTRACTOR EQUIPMENT PRODUCTS WILL BE
MERCHANTABLE OR FIT FOR ANY PARTICULAR PURPOSE. SOUTHWIRE MAKES NO OTHER WARRANTY,
EXPRESSED OR IMPLIED, OTHER THAN THE RELEVANT WARRANTY SPECIFICALLY SET FORTH IN THIS
WARRANTY SECTION. SOUTHWIRE WILL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL,
INDIRECT, SPECIAL, OR PUNITIVE DAMAGES FOR ANY BREACH OF THIS LIMITED LIFETIME WARRANTY.
Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.
1. All warranty claims must be approved by Southwire’s Tools & Assembled Products
Warranty Department prior to return of product. If Southwire determines that a product is
defective, Southwire will, at its option, repair or replace defective products or defective
product components, free of charge.
2. Upon approval, Southwire will issue a Product Return Authorization Form which will include
instructions on how and where to return the product. The product serial number and the
original date of delivery must be set forth on the Product Return Authorization Form.
3. Southwire will cover standard freight charges (Ground Courier Rate) incurred in connection
with products that Southwire ultimately determines to be defective.
4. All defective components and defective products that Southwire replaces under these
Warranties will become Southwire’s property and will be retained by Southwire.